Title: - Visit Report of Transformer Manufacturing Company

Title: - Visit Report of Transformer Manufacturing Company
A transformer consists mainly of the following parts,

1. Core
2. Winding
3. Tank
Transformer core
The core is one of the main parts of the transformer. The core is made up of stamping having a very
small thickness of about 0.1mm. Many such stampings are mounted over one another to make the core.
To have stepped core stampings of different sizes are used. Stepped core is used so that maximum flux is
flows in the core rather than completing its path through air. Minimum 6-7 stepped cores are used. The
adjacent stampings are insulated from each other. The material used in making transformer core is CRGO
(cold rolled grain oriented) steel.
The transformer core stamping have the following shapes which is different for the limbs and yoke
of the transformer resp. these are as shown below.
a)
End limbs
Stamping
b) Yoke stamping c) Central limb stamping
The yoke and the limbs are joined by use of bolts to form the core assembly.
Windings
The transformer usually consists of two windings namely, the h.v winding and the l.v. winding. The
l.v. and the h.v. winding are insulated from each other. The insulation used is the insulation paper of
class F. The thickness of the insulation provided is of about 10mm. The l.v. and h.v. winding can be
easily distinguished depending on their gauges i.e. c/s area. The h.v winding has an smaller c/s area as it
has to carry small amount of current whereas the l.v. winding has a large c/s area compared to the h.v.
since it has to carry more current. The l.v. winding is always placed near the core since it works at a lesser
voltage therefore less insulation is needed between the core and the winding.
The winding is wound externally and then are transferred over the core. The winding is wound using
the motors externally which have a counter attached to it. The counter keeps the record of the rotation of
the motor which indirectly is the measure of the number of turns.
The material used for windings is copper. The copper wires have a coating of varnish which is an
insulator and it prevents the short circuit between the conductors. Tap changers are employed for the
purpose of changing of the turns on either l.v. or the h.v. to change the voltage. Usually the tap changer is
provided on the primary side of the transformer.
Tank
The whole transformer core assembly is placed in the transformer tank. The transformer tank is filled
up with the insulating oil known as transformer of which serves as a coolant which takes away the heat
from the windings. The auxiliary equipments required for proper functioning of the transformer are
mounted on the tank.
The following parts can be easily visualized on the tank, they are
1. BUCHHOLZ RELAY :It is a very sensitive gas and oil operated instrument which safely detect
the formation of gas or sudden pressure inside the oil transformer.
2. CONSERVATOR: it is used to provide adequate space for the expansion of oil when transformer
is loaded or when ambient temperature changes.
3. SILICA GEL BREATHER: It sucks the moisture from the air which is taken by transformer so
that dry air is taken by transformer.
4. DOUBLE DIAPHRAGM EXPLOSION VENT: It is used to discharge excess pressure in the
atmosphere when excess pressure is developed inside the transformer during loading.
5. OIL LEVEL INDICATOR: It is used to show the oil level in the transformer.
6. WINDING TEMPRATURE INDICATOR : used to show the temperature of transformer
winding.
7. RADIATORS: these are used for cooling of the transformer oil.
Process of Manufacturing of a transformer
The transformer is assembled step by step in certain fashion as described below.

1. The first step in the manufacturing of the transformer is the assembling of the core. The core is
made up of stampings of different sizes. The no. of stamping of a particular size to be used
depends upon the rating and the steps required. Each limb and yoke are stamped individually
and then bolted together. Great care is taken for during formation of the core. Any irregularity
may lead to the increase in the losses of the transformer.
2. Secondly the windings are mounted on the core. Initially the winding are wound separately with
the calculated number of turns. Before mounting the winding a layer of the insulation is placed
over the core. To mount the winding the yoke is dismantled from the limb and first the l.v.
winding is placed. Over this l.v. winding layer a layer of insulation is placed and over this the h.v.
winding is mounted and again a layer of insulation is placed. The end terminals are brought out
and connected as per requirement are connected in star or delta and other ends are brought out at
the terminal box.
3. Once the winding is placed over the core, this whole assembly is placed in the tank and closed.
The transformer oil poured into the tank from top up to the level half of the conservator which is
indicated by the oil level gauge. The height of the conservator is kept above the bushing in order
that the whole core assembly is immersed into oil and the bushings are filled up with the oil. The
air in the tank is removed out through the air vent.
4. After all the assembling of the transformer it has to undergo some tests. The following tests are
carried over it and it is put into service. The tests include ,
a. No load test
b. Open circuit and Short circuit test :- This test is carried out to get the information about the
losses , efficiency and regulation of the transformer.
c.H.V. test :- This test is carried out by applying a voltage which is 2.5 times more than the rated
voltage for an time duration of 1minute and ability of the transformer to sustain momentary
high voltage is checked.

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Title: - Visit Report of Transformer Manufacturing Company

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Title: - Visit Report of Transformer Manufacturing Company

A transformer consists mainly of the following parts,

b) Yoke stamping c) Central limb stamping

Process of Manufacturing of a transformer

The transformer is assembled step by step in certain fashion as described below.

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